PREDICTIVE MAINTENANCE

Sensors – generating data

The first element of a predictive maintenance system is sensors to collect data, ideally configured for continuous, real-time monitoring.

Vibration and temperature sensors are the workhorses of predictive maintenance. They provide an effective picture of the health of an asset (e.g., bearing, motor, pump, etc.) and unlock significant diagnostic and predictive capabilities. Sensors can be analog or digital, and wireless or wired.

Pressure sensors can enable filter replacements based on operational data vs. purely time-based replacement cycles and can enable continuous improvement projects with fine tuning of operational parameters.

Current monitoring sensors can enable higher precision monitoring of critical motors and identify problems being caused by controller issues.

Data acquisition – capturing data

Once sensors are in place, the data they produce needs to be collected and converted – think 4.6 volts -> 130 degrees Celsius in the case of analog sensors. This could take the form of sending analog signals to a programmable logic controller (PLC) and recording in the data historian or a base station receiving data wirelessly and uploading to cloud-based analytics tools.

Data analytics – leveraging data

This is where predictive maintenance systems succeed or fail and it’s the hardest element to get right.

You now have thousands, hundreds of thousands, or potentially millions of data points that need to turn into “Bearing 17A is under lubricated” or “Motor 63B is showing signs of bearing failure”.

This is where IGE’s asset monitoring system powered by KCF Technologies is really differentiated. KCF’s clear, intuitive platform leverages decades of experience from thousands of installations to deliver actionable insights. With automated alerts, trend analysis, and customizable dashboards, SMARTdiagnostics enables maintenance teams to eliminate unplanned downtime, reduce costs, and optimize asset performance.

Even relatively simple data analytics can deliver real value. For example, identifying that a bearing is hot and vibrating and replacing it during a planned downtime vs. upon later failure resulting in unplanned downtime can deliver tens of thousands of dollars in savings.

Turning data into work orders that prevent unplanned downtime and reduce costs is what this is all about.

IGE’s recommended predictive maintenance system is built on KCF’s wireless, magnetic vibration & temperature sensor. They are rugged, cost-effective sensors that are easy to set up (no wiring!) and run on a widely available battery that can last up to five years (depending on measurement frequency).

Sensors send data to a KCF base station, which can cover 100 sensors and runs on a protocol that does not interfere with plant wifi. The base station sends data to KCF’s SMARTdiagnostics, which is a web-based platform with automated alerts, trend analysis, and customizable dashboards. Easily & immediately identify issues like an overlubricated bearing, an underlubricated bearing, misaligned belts, impeller imbalance, belt failure and more.

To maximize the potential of your predictive maintenance program, KCF also offers SENTRYsolutions – 24/7 monitoring by their team of Mobius Certified Cat II and III vibration analysts and ongoing optimization to continuously improve efficiency and reliability.

The most effective (and highest ROI) implementations tend to be complete coverage of addressable assets including fan bearings, fan motors, pumps, gear boxes, other bearings, other motors, etc. Customers typically see a 10x+ return on their investment.

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IGE FANS field diagnostic kit powered by KCF Technologies

Flexible, asset health assessment field kit

If you’re looking to equip your maintenance team with the right tools to diagnose problematic equipment, look no further. Get the same technology powering the asset monitoring solution above, but on a smaller scale. The kit includes a base station and a flexible number of vibration & temperature sensors for self set up.
Quickly identify what is driving the poor service life of a motor or a bearing on specific machine. Address the root cause, then redeploy the sensors to the next priority asset in minutes. 

DIY sensor integration into existing control systems

Leverage existing systems to take your first steps towards predictive maintenance

Looking to integrate basic vibration or temperature monitoring into your existing control and data collection systems? From recommending sensors and their positioning to setting alarm levels, IGE is here to help you improve the reliability of your equipment – whether it includes IGE FANS equipment today or not.